Panel assembly for a concrete panel forming system

ABSTRACT

A panel assembly for use in a concrete panel forming system having a pair of elongated, spaced apart and parallel side rails where each rail has a top and a bottom end. A top rail and a bottom rail each have spaced apart ends. The top rail is arranged so that the top rail ends are adjacent the top ends of the side rails and, similarly, the bottom rail ends are adjacent the bottom ends of the side rails. The corner pieces, L-shaped brackets and rails are then attached together by rivets. A sheet overlies and is secured to one side of the rails. Additionally, a plurality of cross supports extend between the side rails to support the sheet. An end portion of each rail is sandwiched in between an L-shaped inner corner piece and an outer L-shaped bracket.

BACKGROUND OF THE INVENTION

I. Field of the Invention

The present invention relates generally to concrete panel forming systems and, more particularly, to a panel assembly for such a system.

II. Description of Related Art

In order to form poured concrete walls, it has become conventional practice to utilize concrete wall forms to form the cavity into which the concrete is poured. These concrete wall forms are typically constructed from rectangular panels that are secured together in a side-by-side relationship in order to form the concrete-receiving cavity.

The panels which form the concrete wall forms have been constructed of several different materials. For example, wood panels constructed from plywood sheets supported by wooden studs were utilized for a long period of time. Such wall form panels, however, easily become damaged and require replacement.

More recently, concrete forming panels constructed of metal, typically aluminum, have been utilized in lieu of the previously known wooden concrete forming panels. Such metal concrete forming panels enjoy long life, high strength and relatively low cost.

These previously known aluminum panels typically comprise a pair of spaced apart and parallel elongated side rails having an elongated top rail extending across their upper end and a bottom rail extending across their lower end. The abutting ends of the top, bottom and side rails are then welded together. Thereafter, an aluminum sheet is secured across one side of the rails and this sheet is supported by a plurality of vertically spaced and horizontally extending cross supports.

In order to strengthen the welded connection between the side rails and the top and bottom rails, a gusset has been traditionally welded across each corner as well as the aluminum sheet. Unfortunately, these gussets have been unable to prevent breakage of the weld at the corner whenever the panel is subjected to abuse. Such abuse occurs, for example, when the aluminum panel is dropped into a hole and the panel impacts on one of the corners. When this happens, the welded connection between the side rail and the top or bottom rail is subjected to such stress that the weld breaks despite the reinforcing gusset.

A still further disadvantage of these previously known panels is that the cross members are typically constructed from square or rectangular metal tubing which is welded along both sides to the sheet. Such tubing, however, is relatively expensive in material cost and the cost for welding the cross support along its entire length is also high in both labor and material costs.

SUMMARY OF THE PRESENT INVENTION

The present invention provides a panel for a concrete forming panel system which overcomes all of the above-mentioned disadvantages of the previously known panels.

In brief, the panel includes a pair of elongated, spaced apart and parallel side rails wherein each side rail includes both a top end and a bottom end. The rails are constructed of aluminum and preferably comprise an aluminum extrusion.

A top and bottom rail are also provided, and both the top and bottom rail each have spaced apart ends. The top rail is arranged so that the top rail ends are adjacent the top ends of the side rails. Similarly, the bottom rail is arranged so that the bottom rail ends are adjacent the bottom ends of the side rails.

In order to secure the side rails to both the top and bottom rails, an L-shaped inner corner piece is positioned in abutment on the inside surface of the rails at all four corners of the panel, i.e. between the top ends of both side rails as well as the bottom ends of the side rails and both ends of the bottom rail. An L-shaped bracket is then positioned in abutment with the outside surface of the rails of each corner so that each end of each rail is sandwiched in between the inner corner pieces and the L-shaped brackets. The brackets, rails and corner pieces are then secured together by appropriate fasteners, such as rivets. The corner pieces and L-shaped brackets are preferably made of stainless steel for high strength and durability.

A rectangular sheet, also constructed of aluminum, is then secured by welding to one side of the rails and corner pieces. At least one and preferably a plurality of vertically spaced elongated cross supports, also constructed of aluminum, then extend between the side rails. These cross supports are generally U-shaped in construction and have their open side in abutment with the sheet. The open sides of the cross supports are then secured to the sheet by intermittent welds while the space in between each pair of intermittent welds is then sealed against fluid by any appropriate sealant, such as silicone or other caulk.

The prime advantage of the panel of the present invention is that the corner pieces reinforce the panel. Consequently, an impact on the corner of the panel of the type that might be caused by dropping the panel into a hole is insufficient to break the connection between the corner pieces and the rails.

A still further advantage of the present invention is that each of the cross supports are generally U-shaped in construction having their open side in abutment against the sheet. This construction reduces the material cost of the cross supports as compared to the previously known cross supports. In addition, since the cross supports are only intermittently welded to the sheet, the material and labor cost to weld the cross supports to the sheet is lower than the previously known panels.

BRIEF DESCRIPTION OF THE DRAWING

A better understanding of the present invention will be had upon reference to the following detailed description, when read in conjunction with the accompanying drawing, wherein like reference characters refer to like parts throughout the several views, and in which:

FIG. 1 is a plan view illustrating a panel in a preferred embodiment of the present invention;

FIG. 2 is a fragmentary exploded view illustrating one corner of the panel;

FIG. 3 is a fragmentary partial sectional exploded plan view of one corner of the panel;

FIG. 4 is a sectional view illustrating one corner of a completed panel;

FIG. 5 is a fragmentary partial sectional elevational view illustrating a cross support and its attachment to the panel;

FIG. 6 is a sectional view taken substantially along line 6-6 in FIG. 1;

FIG. 7 is a view taken substantially along line 7-7 in FIG. 1;

FIG. 8 is a view similar to FIG. 7, but illustrating a modification thereof; and

FIG. 9 is a view similar to both FIGS. 7 and 8 but illustrating a further modification thereof.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

With reference first to FIG. 1, a panel 10 for a concrete forming panel system is shown having a pair of elongated side rails 12, an elongated top rail 14, and an elongated bottom rail 16. Each side rail 12 includes an upper end 18 and a lower end 20. Similarly, the top rail 14 includes a pair of spaced apart ends 22 while the bottom rail 16 includes a pair of spaced apart ends 24. All of the rails 12, 14 and 16 are constructed of aluminum and preferably comprise an aluminum extrusion.

With reference now to FIGS. 2-4, an L-shaped corner piece 26 is provided at each corner of the panel 10 so that the corner piece 26 abuts against an inside surface of the rails 12-16 at the ends of the rails 12-16. Each corner piece 26 is constructed of stainless steel for high strength and durability.

Each corner piece 26 includes a pair of legs 28 which intersect each other perpendicularly at a corner 29 of the corner piece 26 and are welded together at the corner. A plate 32 extends along and is attached to one side 34 of the legs 28. Preferably, the plate 32 and legs 28 are of a one-piece construction. Preferably, the legs 28 flatly abut against their associated rail 12 or 14 as best shown in FIG. 2.

As best shown in FIGS. 3 and 4, an L-shaped bracket 100 having two legs 102 and 104 is positioned in abutment with an outer surface of the rails 12-16 at each corner so that an end of each rail 12-16 is sandwiched in between the L-shaped bracket 100 and the corner piece 26. The L-shaped brackets 100, rails 12-16 and corner pieces 26 are then secured together by appropriate fasteners, such as rivets 42. However, other fastening means, such as welding, may alternatively be used without deviation from the spirit or scope of the invention.

Each L-shaped bracket 100 is preferably constructed of stainless steel for high strength and durability. Additionally, each leg 102 and 104 of each L-shaped bracket 100 preferably includes a reduced thickness end portion 106 which nests within a mating recess 108 (FIG. 3) on the rails 12-16 so that an outer surface of the L-shaped brackets are flush with the outside surface of the rails 12-16. For example, assuming that the thickness of the rails 12-16 is three-eighths of an inch, the thickness of the L-shaped bracket 100 at the corner is preferably one-quarter inch while the thickness of the end portions 106 of each L-shaped bracket is one-eighth of an inch. The width of the L-shaped bracket 100 is substantially the same as the rails 12-16.

With reference now to FIGS. 1 and 5, after the corner pieces 26 have been attached to the rails 12-16, a metal aluminum sheet 50 is positioned across the rails 12-16. Preferably, each of the rails 12-16 include a longitudinally extending notch 52 into which the sheet 50 fits. The sheet is also constructed of aluminum and secured to the rails by welding.

Referring now to FIGS. 1 and 5-7, a plurality of elongated cross supports 60 extend between the side rails 12 at vertically spaced positions therealong. The cross support 60 is generally U-shaped and has its open side 62 in abutment with the sheet 50.

A plurality of longitudinally spaced and intermittently formed welds 66 between the open side 62 of the cross support 60 and the sheet 50 secure the cross supports 60 to the sheet 50.

As best shown in FIG. 1, these welds 66 are spaced apart from each other and a sealant 68 is optionally provided between each pair of adjacent welds 66 to fluidly seal the interior of the cross support 60. Any conventional sealant 68, such as silicone or other caulk, may be used.

Additionally, as best shown in FIG. 1, the cross support 60 is secured to each side rail 12 by a weld 70.

With reference now to FIGS. 8 and 9, FIG. 8 illustrates a cross support 60′ having an alternative cross sectional shape. Likewise, FIG. 9 illustrates a cross support 60″ having still a further different cross sectional shape. Different cross sectional shapes may be required in view of the pin placements (not shown) along the side rails 12 of the panel as well as panels of different widths.

From the foregoing, it can be seen that the present invention provides several advantages over the previously known panels for concrete forming panel systems. In particular, the provision of the corner pieces to secure the top, bottom and side rails together strengthens the overall panel and minimizes the likelihood of damage to the panel that might otherwise occur by dropping the panel on its corner or by other abuse to the panel.

Additionally, the provision of the U-shaped cross supports reduces the overall material cost as compared to the previously known cross supports using square metal tubing. Also, by only intermittently welding the cross support 60 to the sheet, both labor and material cost for securing the cross supports to the sheet are reduced as compared to the previously known systems.

Having described my invention, however, many modifications thereto will become apparent to those skilled in the art to which it pertains without deviation from the spirit of the invention as defined by the scope of the appended claims. 

1. A panel for use in a concrete forming panel system comprising: a pair of elongated, spaced apart and parallel side rails, each side rail having a top end and a bottom end, a top rail and a bottom rail, said top rail and said bottom rail each having spaced apart ends, said top rail being arranged such that said top rail ends are adjacent said top ends of said side rails, said bottom rail being arranged such that said bottom rail ends are adjacent said bottom ends of said side rails, four L-shaped corner pieces, one corner piece being positioned in abutment with an inside surface of each end of said top rail and said top ends of said side rails and in abutment with an inside surface of each end of said bottom rail and said bottom ends of said side rails, an L-shaped bracket positioned in abutment with an outside surface of each pair of adjacent rails so that an end of each rail is sandwiched between said L-shaped bracket and said corner piece, at least one fastener for fixedly securing said L-shaped bracket, said corner piece and said rails together, and a sheet overlying and secured to one side of said top, bottom and side rails.
 2. The invention as defined in claim 1 wherein said side, top and bottom rails each include a recess at each of their respective outer ends, each L-shaped bracket having portions which nest within said recesses of the rails adjacent each said corner piece.
 3. The invention as defined in claim 2 wherein said each L-shaped bracket is secured to its adjacent rails by rivets.
 4. The invention as defined in claim 1 wherein said rails and said corner pieces are constructed of aluminum.
 5. The invention as defined in claim 1 wherein said corner piece is constructed of stainless steel.
 6. The invention as defined in claim 1 wherein each corner piece comprises a pair of legs which perpendicularly intersect each other, and a plate extending along one side of said legs and secured to said legs.
 7. The invention as defined in claim 6 wherein said legs and said plate are of a one-piece construction.
 8. The invention as defined in claim 1 and comprising at least one elongated cross support extending between said side rails, said cross support being secured to said sheet.
 9. The invention as defined in claim 8 wherein said cross support is secured to said sheet by welding at least a portion of said cross support to said sheet.
 10. The invention as defined in claim 8 wherein said cross support is generally U-shaped in cross section having an open side, said open side of said cross support abutting against said sheet.
 11. The invention as defined in claim 8 wherein said cross support is secured to said sheet by intermittent welds along said cross support, and further comprising a sealant disposed between said intermittent welds which fluidly seals said cross support to said sheet.
 12. The invention as defined in claim 8 wherein both ends of said cross support are secured to said side rails by welding.
 13. The invention as defined in claim 8 wherein said cross supports are made of aluminum.
 14. The invention as defined in claim 1 wherein each L-shaped bracket comprises a pair of legs, each leg having a reduced thickness outer end portion. 